Chilling and ice making system and methods

ABSTRACT

There is provided a product merchandising display device for cooling products therein and associated methods. The product merchandising display device may include a housing having a tub portion, and a source of water to supply an integrated ice making system. The ice making system dispenses ice into the tub portion, and melted water is removed from the tub portion and recycled to the production of ice by the ice making system. The system provides an interactive experience to the consumer to enhance its attractiveness and impulse sales therefrom. The invention provides an attractive, inviting display in which the articles for sale are made conveniently accessible while providing a display of light and movement of ice to attract the consumer.

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority to and the benefit of U.S. Provisional Patent Application No. 61/561,985, filed on Nov. 21, 2011, and is incorporated herein by reference in its entirety.

TECHNICAL FIELD

This invention relates generally to product merchandising units for use in storing and displaying a wide variety of products to consumers and, more particularly, to a merchandising unit that includes a ice making system and cooler receptacle forming a point of sale product merchandising unit for holding and merchandising chilled products therefrom.

BACKGROUND OF THE INVENTION

In the sale and merchandising of various products, such as single unit products like bottled or canned drinks, fruit juice type beverages, some food items and the like, it is desired to pre-chill such products for immediate consumption. Many convenience or other stores have large refrigerated cases that may allow for this. These wall-mounted, refrigerated product displays are used, but have various deficiencies from the standpoint of promoting effective impulse buying. Either only the front panel or door of such display devices is clear, and the products are displayed in a package form or, if in a single unit, in a disadvantageous marketing position. In addition, wall-mounted units typically are very large and/or permanently mounted in a particular aisle, and thus not portable to various locations around the store or to other locations. A wide variety of products such as soft drinks, fruit juices, beer, wine, prepared sandwiches and the like, might sell much more quickly if the display system could be placed at a location near the checkout counter of the store or other areas of high customer traffic. Impulse buying is effective only when the product is located within the customer's view, and very large or permanently mounted wall units often are located in areas of low customer traffic.

To facilitate impulse purchasing of such items, there is a need to have a product merchandising unit which will accommodate the storing and chilling of a reasonable number of such articles for easy access by prospective customers. This is particularly true in the mobile society in which we live, where pre-chilled beverage and other products are many times purchased for consumption on the go. As a result, point-of-sale merchandising units are widely used due to the greater flexibility provided with respect to where such merchandising units may be located. The strategic location of such units can have a significant impact on the sales of the articles or products. The ability to provide merchandising units immediately adjacent areas such as food counters, points of purchase, and other high customer traffic locations, provide better utilization of merchandising areas, and is important to the merchant.

There is thus a need for other point-of-sale merchandising systems, and merchandising units have thus been developed which are formed as open coolers, using non-renewable amounts of ice cubes in a tub or container, in which the products are placed to pre-cool them. Though somewhat effective, such units have deficiencies in that they must be manually refilled with ice from an outside source as the ice turns to water. If not properly filled with ice, the units may not cool the temperature of the products that need to be cooled uniformly, resulting in a product being sold at an undesired temperature. Further, it is desirable for such units to have a sufficient volume to hold enough product and ice to satisfy periods of high consumer demand, such as on weekends, holidays, and other high consumer traffic periods. At the same time, as the ice in the unit begins to melt, it either creates a body of water in which the products are disposed, or if the water is drained, does not allow for desired display and access to the products that sink into the tub. With such units, it is also possible that the ice and water become contaminated from customers having to put their hand into the ice/water to retrieve an item. It would be desirable to provide a system for automatically sanitizing the ice/water used in the merchandising unit. It may also desirable for the unit to be able to hold a smaller quantity of such products and ice for lower volume periods. This would save costs associated with the ice used in such units. It would be desirable to allow for an effective system to overcome these problems. For these and other reasons, the present invention is directed to overcoming the problems set forth above.

SUMMARY OF INVENTION

The invention overcomes the shortcomings and limitations of the prior art units discussed above and teaches the construction and operation of embodiments of a product merchandising display device adaptable for use in merchandising chilled products.

The invention also provides an interactive experience to the consumer to enhance its attractiveness and impulse sales therefrom. The invention provides an attractive, inviting display in which the articles for sale are made conveniently accessible while providing a display of light and movement of ice to attract the consumer.

Further, the invention provides for a system and method for substantially uniform cooling of products in a product merchandising display, which is maintained without intervention by the merchandiser.

These and other aspects of the invention are embodied within a product merchandising display device for cooling products therein, comprising a housing having a tub portion, and a source of water to supply an integrated ice making system. The ice making system dispenses ice into the tub portion, and melted water is removed from the tub portion and recycled to the production of ice by the ice making system.

The invention also relates to a system and methods for automatically refreshing ice in a merchandising display device for cooling products therein comprising a stand-alone housing having a tub portion, and a source of water to supply an integrated ice making system. The ice making system dispenses ice into the tub portion on an automated basis, and melted water is removed from the tub portion. If desired, the melted water may be recycled to the production of ice by the ice making system.

The invention also relates to a system and methods for displaying and merchandising cooled products that includes at least one visible feature including movement of ice or water around the products during the display thereof.

The invention also relates to a system and methods for sanitizing the ice/water used in the merchandising unit, by filtration or other decontamination of the melted water used in the production of ice for the system.

The system may include further features, such as a movable base system to allow different amounts of product to be accommodated in the tub portion of the system, water recycling systems, sensor and control systems to monitor and control ice, water levels and/or other systems or functions, advertising systems and lighting and/or audio systems for attraction of customers and other features.

DESCRIPTION OF THE FIGURES

The structure, operation and advantages of a presently preferred embodiment of this invention will become further apparent upon consideration of the following Description, taken in conjunction with the accompanying FIGS. and examples, wherein:

FIG. 1 is a front elevational view of a display apparatus according to an example of the invention;

FIG. 2 is a partial cross section of the example of the display apparatus shown in FIG. 1;

FIG. 3 is a partial exploded view of the display apparatus of the example of FIG. 1;

FIG. 4 is a partial exploded view of the display apparatus of the example of FIG. 1;

FIG. 5 is a back perspective view of the ice distribution system according to an example of the invention;

FIG. 6 is a top view of the ice distribution system according to an example of the invention;

FIG. 7 is a flow chart showing operational aspects of an example of the invention; and

FIG. 8 is a schematic illustration of a control system in conjunction with the invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to FIGS. 1-4, one example of a point-of-purchase, product merchandising apparatus 10 of the invention is illustrated. The product merchandising apparatus 10 includes a base 12 and an upper housing 14 mounted atop the base 12. The base 12 and upper housing 14 may be formed of any suitable material, such as plastic, metal or similar material. The upper housing 14 may also have various surfaces 15 which allow for high quality graphics to be displayed, forming a unit that becomes a beautiful and inspirational display in conjunction with other features as will be discussed below. This enhances the ability to attract consumers to try one of the products pre-chilled therein. The panels 15 may be vacuum formed plastic, and the unit may allow for interchangeable graphics to be displayed on the surfaces 15. Backlighting may be provided for enhancing the visibility of the graphics or for producing lighting effects. LED lighting may be used for energy saving and simplicity for example. The base 12 may be constructed to provide stability, and may be supported on the floor by lockable rollers 19, pads or the like, to facilitate transport thereof. In general, the product merchandising apparatus 10 is portable and can be readily moved to different locations at a particular retail establishment, or to different retail or other venue. For example, the apparatus may be used in convenience stores, hotels, convention centers, stadiums, other kiosk applications, events where self-service is desired such as weddings, receptions, casual dining and the like.

The base 12 further includes a tub portion 16 defining an open interior for displaying beverage, food or other items. The tub portion 16 may be formed as a singular space or may be divided into compartments or the like if desired. The interior portion provides the chilling space into which ice and products are disposed for pre-chilling the products for purchase by a consumer. The tub portion 16 has insulation disposed around it to maintain a chilling temperature within the tub portion 12. The tub portion 16 may be formed integral to the base 12 or may be provided as a separate unit that is mounted on the base 12. Though the base 12 and tub portion 16 are shown with a flat back surface, to be disposed adjacent a counter, wall, another system 10 or the like, it could also be formed such that the tub portion extends around the entire housing to be accessible from any direction. The tub portion 16 could also be supported on a lazy-susan type bearing to allow the tub portion 16 to be rotated so as to be visually appealing. Like the upper housing 14, the base 12 may also have various surfaces 18 which allow for high quality graphics to be displayed. The larger surfaces 18 of the base 12 allow for a wide variety of graphics/advertising to be displayed, to enhance attracting consumers to try one of the products pre-chilled therein. The panels 18 may be vacuum formed plastic, and the unit may allow for interchangeable graphics to be displayed on the surfaces 18. Backlighting may be provided for enhancing the visibility of the graphics or for producing lighting effects, such as by LED lighting. There may also be provided an audio generating system in the upper housing 14 and/or base 12, to play sound/music or other audio. Other devices to enhance the visual or other appeal of the system 10 may be used, such as video displays for example. Further, it may be desirable to form the tub portion 16 to have a variable volume to assist in storing different quantities of products therein. To allow for this, the position of the bottom surface of the tub portion may be made to be adjustable, either manually or automatically, to adjust the volume of the tub portion. In this way, for times of lower volume activity, the volume of the tub portion 16 may be reduced to hold less product, but to display it in a visually appealing manner. In some cases, if a lower volume of products is placed in a tub portion of a greater volume, the appearance of the display of products may not be as desired, and vice versa, so it may be desirable to provide the system 10 with such volume adjustment capability. It is also possible to provide additional attributes in association with the tub portion 16, such as individual holders for beverages or other products disposed around the tub portion 16 to allow display of such items in a desired manner. It may also be possible to provide an automatic product dispensing system which could be used to automatically refill the tub portion with a desired amount of product after chilled product has been taken therefrom. It may also be desirable to provide a product distribution system to allow products to be refilled in a somewhat uniform manner around the tub portion 16.

The upper housing 14 includes an integrated ice making system 20 as seen in FIGS. 2 and 4, which is mounted over the tub portion 16 to automatically and controllably dispense ice into the tub portion 16. One or multiple units 20 may be used as may be desired. The ice maker may 20 be of any suitable design, but as an example, may be designed to instantly make clear ice when actuated. The ice maker 20 may be a crystalline ice bullet head, and may be selectively controlled to make different ice cube sizes. The maker 20 may include an ice management system, and be designed to allow for production of a predetermined amount of ice in response to the environment in which the unit 10 is used. A temperature sensor may monitor the temperature of the local environment and if the ambient temperature is hot, then the freeze cycle time of ice maker 20 may be lengthened to produce consistent ice cube size. If the ambient temperature is cool, then the freeze cycle time of ice maker 20 may be shortened to produce consistent ice cube size. A temperature sensor may also be used to monitor the temperature in the tub portion 16. When ice has been produced to create a predetermined temperature in the tub portion 16, ice production is stopped until ice in the tub portion 16 has melted to a degree and then the ice maker 20 is turned back on. The ice maker 20 may be controlled to produce consistent ice cube sizes and keep the tub portion 16 full of ice as desired. The ice maker 20 could also be controlled to produce a predetermined ice per time period, such as 12 ice cubes per 10 minutes, or other suitable amount. The ice maker 20 may have a predetermined ice capacity, such as between 25 to 40 pounds per 24 hours. The maker 20 may include a water level control or management system to ensure proper operation, and may use a control system to automatically control operation. For example, the control system may allow for programmable operation, to allow features such as automatic On/Off features based on opening hours of a retail store, automatic water level control or management and shut-off features based on low water levels, power saving features, temperature sensor control based on local environment, and other desired functions or characteristics. The control system may also be configured to allow two units 10 to be disposed back-to-back for example, with the control systems of the multiple units working together in a coordinated manner, such as by forming a master/slave configuration between the units.

Turning to FIG. 8. in an example, a control system 150 may include a central processing unit (CPU), programmable logic controller (PLC) or other suitable system, that is suitably programmed to implement desired operation of the units 10. As shown in this example, alternative example of the unit 10 includes a visual or light indicator 160, such as one of more LED's, and sound alert indicator 162, associated with a control panel 164 on the back of unit 10. Another light indicator 166, such as one of more LED's, may be provided on a front indicator panel 168. The light indicators 160 and 166 in the front and back allow clear communication of the operation of unit 10 for ensuring proper operation. Further, the sound alert indicator 162 in conjunction with the light indicators enables alerting personnel to any problem or need for attention to continue desired operation of unit 10. The control system 150 may thus include a light and sound indicator control 152 connected to the light indicators 160 and 166, and to sound alert indicator 162. The CPU is set via a control 154 to either preset parameters for operation of the unit 10, or User settings, that may be input by the user to accommodate particular environmental or other conditions or requirements. Further, a water sensor control and/or motor control 156 may be provided in association with a suitable sensor connected with the ice machine 20 and/or suitable motor controller to operate ice dispensing characteristics. If the ice machine 20 is not being supplied with sufficient water, an alert may be provided by the light and/or sound indicators 160, 162 and/or 166. Suitable maintenance or repair can then be initiated. Similarly, a height of ice and/or temperature control 158 may be provided in association with a suitable ice height and/or temperature sensor connected with the ice bin or tub portion 16. If the ice in tub portion 16 is not at a desired height and/or providing the desired temperature within the tub portion, an alert may be provided by the light and/or sound indicators 160, 162 and/or 166. Suitable maintenance or repair can then be initiated. Also, a water level sensor control 159 may be provided in association with a suitable water level sensor connected with the water tank or reservoir 30 of unit 10. If the water reservoir 30 does not have enough or is not being supplied with sufficient water, an alert may be provided by the light and/or sound indicators 160, 162 and/or 166. Suitable maintenance or repair can then be initiated. In operation, the control system 150 may control operation of the ice maker 20 using a water sensor to detect inside water level, the temperature sensor to control the timing of making ice, and/or to control operation of the motor to control the motion or dispensing characteristics of the ice maker when it drops ice. Other sensors or controllers may be used if desired, such as in association with a water pump 32 or associated filter or the like as described below, one or more fans to cool motors/pumps or other components of unit 10, or the like.

There is also provided an ice distribution system 22 mounted below the ice making system 20 that facilitates uniform distribution of ice into the tub portion 16. In this example, the ice distribution system 22 is shown in FIGS. 5 and 6, is a member that slopes outwardly from a top portion thereof. In position, the top is adjacent the location of dispensing ice from the ice making system 20 and system 22 is tapered outwardly to a position above the tub portion 16. As the ice making system 20 is disposed above the tub portion 16, ice dispensed therefrom is directed by gravity to the open tub portion 16. As an example, the ice distribution system 22 may be formed into a simulated shape, such as a mountainside type shape or some other natural or manufactured shape or object. The ice distribution system 22 may also include several channels 24 or other guides to allow ice dispensed from the ice making system 20 in a substantially uniform manner into the tub portion 16. The ice making system 20 may also have an ice distribution controller, such as a motor and associated ice handling system, to allow ice once it is made to be distributed at a desired location relative to the ice distribution system 22. The ice distribution controller could be one or more chute type of members that can be stationary or movable by a motor controller for example. In addition, the ice distribution system 22 provides a visually appealing feature in association with the unit 10, as ice dispensed from the ice making system is directed to slide down the extending surface of the ice distribution system 22. The ice distribution system 22 may be vacuum formed plastic for example, and backlighting may be provided for producing dramatic lighting effects. Other visually appealing characteristics could be utilized, such as dispensing water, mist or the like, along with ice.

As seen in FIG. 4, the system includes functions to support the production of ice and other attributes of the system, comprising a water reservoir 30 for containing an amount of water to support ice production. A water pump 32 is provided and pumps water from reservoir 30 to a filtration system 34. The water filtration system may be of any suitable type, but preferably includes a solids removal system in addition to filtering to remove any solid materials that may end up in the system. The filtration system may also include a system to remove pathogens such as reverse osmosis and/or ultraviolet (UV-C) systems. As will be described below, after ice production, the ice in the tub portion 16 will melt, and such melted water is drained from tub portion 16 back to the water reservoir 30 via a drain tube 36. In this manner, the system continually decontaminates the water used in the system and allows for the production of clean ice. The water reservoir 30 may include one or more water level sensors associated therewith, to indicate a low, sufficient and/or high water level in the system 10. If a low water level is detected, the system may include some type of alarm or indicator, such as a light and/or sound indicator 160, 162 and/or 166 described above, to inform staff that the water reservoir needs filled. But, as water is recycled in the system 10, the need for refilling is minimized. Alternatively, if a source of water is available at the site of the system 10, the use of a water reservoir may be optional, and the water source could be directly connected to the ice making system. If a separate water source is used, drained water may still be recycled or may be discarded.

Turning now to FIG. 7, the ice cube manufacturing and operation process cycle is shown. First at 100 the water is filled into a tank located at the rear of the cooler from an outside source. At 102 the water is then pumped from the water tank through a water filtration system at 104. The filtered water is then pumped to the ice cube maker contained in the housing above the cooler tray. The ice maker is then operated to implement an ice production cycle at 106, and to dispense the newly formed ice cube out of the ice cube maker and dropped to the cooler tub via a the ice distribution system such as via the multi-way channels. The ice cubes then distribute themselves evenly around the product in the cooler tub to reduce the temperature of the product. As the ambient temperature is higher than that of the ice cubes the ice cubes turn into water and drain down to the water tank at 108 via at least one drainage hole located in the base of the cooler tub and is recycled to the ice maker for further ice production. As the recycled water decreases by evaporation the operator must refill the water tank.

It should be evident from the foregoing that the system 10 provides many attributes, including that the system requires less maintenance to operate at optimum operating levels because the melted ice cubes can be replaced with new ones automatically. Further, the filtration system ensures any solid material is removed ensuring the ice cubes appear more uniform. Due to the effect of gravity on the ice cubes as they are released from the top of cooler and guided down to the cooler tub, the ice distribution system 22 ensures equal distribution of ice ensuring the whole tub is being cooled, not just in one section. This effect also captures the consumers' attention and resembles that of a mountain avalanche or water bead on a bottle.

Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the instant invention will include all embodiments falling within the scope of the appended claims. 

What is claimed is:
 1. A product merchandising system, comprising: a housing system supporting a tub portion, a source of water and an ice making system at a position above the tub portion, wherein ice produced by the ice making system is dispensed by gravity into the tub portion.
 2. The product merchandising system of claim 1, wherein the source of water is a water reservoir provided in the housing system.
 3. The product merchandising system of claim 1, further comprising the tub portion having at least one drain therein, wherein water melted from ice dispensed into the tub portion is drained to the water reservoir.
 4. The product merchandising system of claim 3, wherein water drained from the tub portion is recycled to a water reservoir for use in further ice production.
 5. The product merchandising system of claim 1, further comprising an ice distribution system for causing distribution of ice dispensed from the ice making system around the tub portion.
 6. The product merchandising system of claim 1, further comprising an ice distribution control system for causing distribution of ice dispensed from the ice making system to different location around an ice distribution system.
 7. The product merchandising system of claim 5, wherein the ice distribution system is formed into a shape to cause distribution of ice to different locations in the tub portion.
 8. The product merchandising system of claim 5, wherein the ice distribution system is formed into a simulated shape of a natural or manufactured object.
 9. The product merchandising system of claim 1, further comprising a filtration system for filtering water before being pumped to the ice making system for production of ice.
 10. The product merchandising system of claim 1, further comprising a control system for controlling operations selected from the group consisting of ice production, ice cube size, ice distribution, sound effects, lighting and/or backlighting effects, water level management, allowing a plurality of merchandising system to operate together in a coordinated manner, sound alerts, visual alerts, power saving operations, on/off operations, operation shut downs, temperature control, and combinations thereof.
 11. A product merchandising system, comprising a housing having a tub portion and an ice making system for automatically refreshing ice disposed in the tub portion, wherein the housing system is a portable, stand-alone housing to allow positioning of the system at a desired location for displaying chilled product within the tub portion.
 12. The product merchandising system of claim 11, further comprising a water reservoir provided in the housing.
 13. The product merchandising system of claim 12, further comprising the tub portion having at least one drain therein, wherein water melted from ice dispensed into the tub portion is drained to the water reservoir.
 14. The product merchandising system of claim 11, further comprising an ice distribution system wherein the ice distribution system directs ice produced by the ice making system around the tub portion.
 15. The product merchandising system of claim 11, further comprising a filtration system for filtering water before being pumped to the ice making system for production of ice.
 16. The product merchandising system of claim 11, further comprising a control system for controlling operations selected from the group consisting of ice production, ice cube size, ice distribution, sound effects, lighting and/or backlighting effects, water level management, allowing a plurality of merchandising system to operate together in a coordinated manner, sound alerts, visual alerts, power saving operations, on/off operations, operation shut downs, temperature control, and combinations thereof.
 17. A product merchandising system, comprising a housing having a tub portion and an ice making system disposed above the tub portion for automatically refreshing ice disposed in the tub portion, wherein the system includes at least one visible feature including movement of ice or water from a different position within the housing into the tub portion.
 18. The product merchandising system of claim 17, further comprising a water reservoir provided in the housing, and wherein the tub portion has at least one drain therein, wherein water melted from ice dispensed into the tub portion is drained to the water reservoir.
 19. The product merchandising system of claim 17, further comprising a filtration system for filtering water before being pumped to the ice making system for production of ice.
 20. The product merchandising system of claim 17, further comprising an ice distribution system formed into a shape to cause distribution of ice to different locations in the tub portion. 